Frame for interchangeably supporting one or more air control devices

ABSTRACT

A frame mounted to the bottom opening of an air duct for supporting a variety of interchangeable air control devices. The frame has a top section with a central opening that permanently mounts to and surrounds the perimeter of the bottom opening of an air duct, and a bottom section which is foldably connected to the top section. The bottom section connects to the top section by means of a hinge joint at one end and a latching mechanism at the other, which together removably holds the bottom section to the top section in a folded and closed position. The bottom section has an interior stepped portion for removably securing an interchangeable air control device. When released, the bottom section swings downward into an open position to allow easy access to the interchangeable air control device.

PRIORITY CLAIM

Priority is claimed to copending U.S. Provisional Patent Application Ser. No. 60/972,160 filed Sep. 13, 2007, which is hereby incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The field of the present invention relates generally to air control devices which may be installed at the outlets of air handling systems to condition and distribute the airflow throughout the affected home, building, or enclosure, and more specifically to a framing system which allows for removable air control devices, such as diffusers, filters, and insulating blocks, which may be attached at the lower opening of residential and commercial evaporative cooler ducts.

SUMMARY OF THE INVENTION

The present invention comprises a frame mounted to the bottom opening of an air duct that can support a variety of interchangeable air control devices. The frame has a top frame section that is permanently mounted to and surrounding the perimeter of the bottom opening of an air duct, and a bottom frame section which is foldably connected to the top frame section. The bottom frame section is connected to the top frame section by way of a hinge joint connecting the two sections at one end. A latching mechanism is located at the other end of the frame, across the central opening and opposite the hinge joint, that together with the hinge joint removably holds the bottom frame section to the top frame section in a folded and closed position. The bottom frame section has an interior stepped portion for removably securing an interchangeable air control device. When released, the bottom frame section swings downward into an open position to allow easy access to the interchangeable air control device.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one embodiment of the present invention;

FIG. 2 is a perspective view of the top frame section of the embodiment shown in FIG. 1;

FIG. 3 is a perspective view of the bottom frame section of the embodiment of FIG. 1;

FIG. 4 is a perspective view of the latching connection of the embodiment of FIG. 1;

FIG. 5 is a perspective view of a removable air control device being installed in the embodiment shown in FIG. 1, the frame being shown in the open position;

FIG. 6 is a perspective view of a removable air control device with a removable air control device having a condensation collection unit attachably connected in accordance with an embodiment of the present invention; and

FIG. 7 is a perspective view of the embodiment of FIG. 1 with a removable air control device installed and the frame being in the closed position.

DETAILED DESCRIPTION

Reference will now be made to the exemplary embodiments illustrated in the drawings, and specific language will be used herein to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Alterations and further modifications of the inventive features illustrated herein, and additional applications of the principles of the inventions as illustrated herein, which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention.

The present invention is a frame for removably holding a variety of air control devices at the discharge opening of an evaporative cooler duct, including such devices as an air filter, a diffuser, or an insulating block to provide insulation between the duct and the enclosed space during the colder winter months. The frame can be manually opened, the air control devices easily installed, replaced or exchanged, and closed again without difficulty, all by a single individual. Furthermore, the frame can be configured to be opened and closed without the need of tooling.

FIGS. 1-7 illustrate one exemplary embodiment of the frame of the present invention permanently mounted around the perimeter of the bottom opening of an air duct. The air duct opening can be of the common design located in the ceiling of an enclosed space, but the present invention works equally well with the air duct located in an upper or lower portion of a wall. Furthermore, while the present invention can be highly effective when used with an evaporative cooler, such as the residential evaporative coolers installed in many homes in dryer climates, nothing should be inferred from the written description, drawings, or claims to limit the present invention to applications involving residential evaporative coolers. The present invention can also be used in conjunction with any residential and commercial air handling systems and ducting system designs.

As shown in FIG. 1, the frame 10 of the present invention has an upper section 20 and a lower section 40. The upper section 20 is permanently mounted around the perimeter of the bottom opening of an air duct (not shown), with the lower section 40 attached to the upper section in the closed and flush position during normal use. As further illustrated in FIG. 1, the lower section swings downward to allow the user to remove, install, or exchange one or more air control devices. The lower section, with the installed air control device, can then swing back upward to re-connect to the upper frame in the closed position.

FIG. 2 illustrates the upper frame section 20, which further comprises an upper frame body 22 which fixably attaches to the ceiling or wall (not shown) of an enclosed space and around the bottom opening of an air duct by means of fastening devices at a plurality of attachment sites 28. The fastening devices can be nails, screws, glue, or any other fastening mechanism for securely holding the frame body against the wall or ceiling, in addition to holding the weight of the lower frame section and the installed air control device. In the embodiment of FIG. 2, the upper frame body 22 has a traditional rectangular shape with a rectangular central opening 21, but either the upper frame body 22 or the central opening 21 can assume an alternative shape, such as a polygon, circle, a semi-circle, or any other shape that may deviate from the traditional rectangular design for efficiency or aesthetics considerations.

The upper frame section 20 can also have one or more rotating attachment devices 24, such as the male or female portion of a hinge, for permanently attaching the lower frame section to the upper frame section. Moreover, the upper frame body 22 can also be configured with one or more latch sites 26, which will generally be located on the upper frame body in a position opposite and across the central opening 21 from the location of the rotating attachment device 24. Additional latch sites may also be located anywhere around the sides of the upper frame body, including at the corners.

One embodiment of the lower frame section 40 of the present invention is shown in more detail in FIG. 3. Like the upper frame section, the lower frame section also has a lower frame body 42 with one or more complementary rotating attachment devices 44 which connect with the rotating attachment devices on the upper frame section to join the two sections together at one end of the frame. The lower frame body 42 can also have one or more complimentary latching devices 46 which mate with the latch sites on the upper frame section and serve to hold the two sections together at the opposite end of the frame. As stated above, additional latches and latch sites can be located anywhere along the perimeter of the two frame bodies to more securely hold the two bodies together in the closed position.

The lower frame section is also configured with a landing site 50 for the air control device. In the embodiment shown, the landing site comprises a boss, ledge, or interior stepped portion 54 formed into and around the inner face 52 of the lower frame body 42.

One embodiment of the latching mechanism is shown in FIG. 4, which illustrates two latch sites 26 formed into the upper frame body 22, and two latching devices 46 attached to the lower frame body 42. In the embodiment shown, the latching devices 46 comprise two flexible clips 48 that are integrally formed with the lower frame body. While in the illustrated embodiment the latching sites are formed into the upper frame body and the latching sites are formed into the lower frame body, in an alternative embodiment the orientation may be reversed, with the latching sites located on the lower body and the latching devices, including the integrally formed clips, attached to the upper body.

Furthermore, the latching mechanism can be comprised of projections and indentations that are integrally formed with the body, as shown, or it can be comprised of individual pieces of hardware that are separately mounted to the upper or lower frame bodies. The prior art is replete with various types of latching devices, commonly used to hold closed cabinet doors and drawers, or to hold together various items of furniture, all of which should be considered to fall within the scope of the present invention. The latching mechanism can be opened and closed manually, and furthermore can be configured for operation with or without the need of tooling. If tooling is required, the tooling can be common such as a wrench or screwdriver, or unique to discourage tampering by unauthorized individuals.

FIG. 5 is illustrative of the frame of the present invention in its open position, with the upper frame section 20 attached to the ceiling around the perimeter of the lower opening of the air duct (not shown), and with the lower frame section 40 swinging down around the rotating attachment device to allow access to the air control device landing site 50 on the lower frame body 42. An air control device 60 having a central media section 62 which covers the face of the air duct when closed and an outer shell 64 can then be installed in the lower frame section. The outer shell 64 of the air control device can have a perimeter support 80 having a contact surface 84 which is complimentary with the boss ledge 54 formed in the lower frame body. When the air control device is installed into the lower frame section, the contact surface 84 and the boss ledge 54 form a contact seal which restricts the passage of air around edges of the air control devices and forces the air to flow through the central media section 62.

The central media section 62 of the air control device 60 can comprise an air filter 70, an air diffuser 72, an insulating block 74, or another air control device which can be employed separately or in combination to condition, control, or restrict the air flowing out of the duct opening. If the central media section 62 is used as an air filter 70 to filter and condition the flow of air, both disposable fiber and mat filters as well as washable electrostatic filters can be used. When the air control device is used as an air diffuser 72, plastic or light weight metal vanes, which can be adjustable, can be installed within and connected to the outer shell 64. And when the air control device is used to seal and insulate the air duct from the enclosed space during the colder winter months, the central media section 62 can become an insulating block 74 formed from any lightweight insulating media which impedes the passage of heat across the insulating block.

Furthermore, nothing in the present disclosure should be inferred to as limiting the central media section 62 to just one type of media. The air control device could be configured as a dual purpose device which provides, for instance, both air filtration and air diffuser capabilities. The central media section 62 can be configured with two layers within the same outer shell 64, with a filtration layer on top and a system of diffuser vanes below.

During the colder winter months when an air control device 60 such as an insulating block is used, it is possible for condensation to build up within the duct above the frame 10. For example, the duct may be connected to a swamp cooler on a person's roof Temperature differences between the outside of the duct and the inside of the duct can cause condensation to form. This condensation can collect on top of the insulating block and even drip into a person's home, potentially causing damage to the insulating block, the ceiling around the frame 10, and even to floor coverings such as carpet that are beneath the frame.

In another embodiment of the present invention, the air control device 60 can have a concave surface 69. The surface can be formed of, or coated with, a substantially water proof material such as plastic. Condensation from the duct that collects on the air control device can be directed toward a condensation collection orifice 63. The orifice can direct the condensation through the air control device and into a condensation collection unit 65. The condensation collection unit can be attached to the air control device in a manner that will enable a user to easily detach the collection unit to empty the condensation. Alternatively, the condensation can be allowed to naturally evaporate, thereby limiting the number of times it is emptied during the winter months.

In one embodiment, the condensation collection unit 65 can be designed to look like a standard light cover. This allows the condensation collection unit to have an aesthetically pleasing appearance in a home, office, or other type of location. In another embodiment, the air control device 60 can include a collar attachment (not shown) centered about the condensation collection orifice to enable a user to attach a standard ceiling light cover below the orifice using the collar attachment. The use of the collar attachment can enable a user to attach a light cover that matches other light covers used throughout the user's house. The standard light cover can be used to collect condensation from the duct, thereby substantially reducing potential damage to a user's ceiling or floor coverings.

The air control device 60 may also be comprised of at least two sections, as illustrated in FIG. 7. A first section 71 can be comprised of the concave surface 69 made of a substantially waterproof material configured to receive condensation and direct the condensation into the condensation collection orifice 63. The substantially waterproof material can also include an outer layer of a substantially hydrophobic or water repelling material configured to deter water droplets. The hydrophobic material can be used to encourage the condensation to flow down the concave surface of the air control device and into the orifice 63 rather than building up on a surface of the air control device. The use of a water repelling or hydrophobic layer can minimize moisture that may lead to the development of mold on the air control device.

A second section 73 of the air control device can be located beneath the concave surface. The second section can be supported by the bottom frame 40. The second section can be comprised of a substantially flat panel having a center opening corresponding with the condensation collection orifice. The flat panel can be a predetermined color and/or texture that may be used to substantially match the color and texture of typical consumer ceilings. A sleeve, collar, or other typical attachment device can be attached about the center opening to enable the condensation collection unit 65 to be connected with to the attachment device. Various types of sleeves or collars can be provided that are of different colors or finishes, such as silver, brass, gold, aluminum, and so forth. The condensation collection unit that is operable to be attached using the attachment device can be shaped to appear as a typical ceiling mounted light fixture cover, as previously discussed. The use of a separate flat panel enables a variety of colors and textures of panels to be provided to enable a user to substantially match the appearance of the panel with their ceiling. The user can then use the first concave surface and the second textured panel to provide insulation in winter months and collect condensation that occurs in the duct while providing an aesthetically pleasing appearance of the cooler duct during the winter months.

FIG. 7 shows the frame 10 of the present invention in its upward and closed position, with the lower frame section 40 secured tightly against the upper frame section 20 by means of the latching devices 44. The central hole in the frame is entirely occupied by the central media section 62 of the air control device, such that the air is forced to flow through the central media section and is restricted from bypassing around air control device by the tight fit between the upper and lower sections of the frame 10 and the outer shell 64 of the air control device.

As discussed above, the present invention provides significant advantages over the prior art, as access to the air control device is greatly facilitated when the lower frame section swings downward, away from the ceiling or wall. This allows the user to replace or exchange the air control device without climbing on a ladder and without having to perform complicated maintenance tasks requiring special skills, physical abilities or tooling. A second advantage is that the air control devices are interchangeable, and even though the central media section may comprise a different material or combination of materials, the outer shell of the various air control devices all have a common shape and form factor, which allows them to be easily installed in the landing site formed into the lower frame. And finally, the air control devices, including the air diffuser, can be made from new and lighter materials, such as lightweight composites or plastics, which allow them to be comfortably manipulated by a single individual. This permits the residential home owner to single-handedly replace air filters during the summer months, or to exchange a dual-use filter/diffuser air control device with an insulating block when winterizing the evaporative cooling system prior to the winter season.

The foregoing detailed description describes the invention with reference to specific exemplary embodiments. However, it will be appreciated that various modifications and changes can be made without departing from the scope of the present invention as set forth in the appended claims. The detailed description and accompanying drawings are to be regarded as merely illustrative, rather than as restrictive, and all such modifications or changes, if any, are intended to fall within the scope of the present invention as described and set forth herein. 

1. A frame mounted to the bottom opening of an air duct for interchangeably supporting one or more air control devices, comprising: a top frame section configured to be permanently mounted to and surrounding a perimeter of a bottom opening of the air duct; a bottom frame section foldably connected to the top frame section, comprising: a hinge portion rotationally attached to the top frame section; a latching portion opposite the hinge portion for removably latching the bottom frame section to the top frame section in a folded and closed position; an interior stepped portion for removably securing an interchangeable air control device; and wherein the bottom frame section swings downward into an open position to allow access to the interchangeable air control device.
 2. The frame of claim 1, wherein the bottom opening of the air duct is in a ceiling of an enclosed space.
 3. The frame of claim 1, wherein the interchangeable air control device further comprises: an outer shell having a form factor complimentary with the interior stepped portion of the bottom frame section; and a central media section for controlling a flow of air through the air control device.
 4. The frame of claim 3, wherein the central media section is selected from a group consisting of an air filter, a diffuser, and an insulating block.
 5. The frame of claim 4, wherein the interchangeable air control device can include two or more applications in the same outer shell.
 6. The frame of claim 1, wherein the interchangeable air control device includes a condensation collection orifice near a center of the device and has a concave surface to enable condensation to be directed into the orifice under a force of gravity and flow through the interchangeable air control device.
 7. The system of claim 6, wherein the concave surface further comprises a substantially water repellant layer configured to direct the condensation towards the condensation collection orifice to minimize standing water on the concave surface that may cause mold.
 8. The fame of claim 6, further comprising a condensation collection unit attachably connected to the interchangeable air control device below the condensation orifice to allow the condensation directed through the orifice to be collected in the condensation collection unit.
 9. The frame of claim 8, wherein the condensation collection unit is shaped as a ceiling light cover.
 10. The frame of claim 8, further comprising a collar attachment centered about the condensation collection orifice to enable a user to attach a standard ceiling light cover below the orifice using the collar attachment.
 11. A mounting system operable to support one or more air control devices, comprising: a top frame section configured to be permanently mounted to and surrounding a perimeter of a bottom opening of an air duct; a bottom frame section hingeably connected to the top frame section, comprising: a hinge portion rotationally attached to the top frame section; a latching portion opposite the hinge portion for removably latching the bottom frame section to the top frame section in a folded and closed position; an interior stepped portion for removably securing an interchangeable air control device; wherein the bottom frame section is configured to swing downward into an open position upon actuation of the latching portion; and at least one air control device operable to be received in the interior stepped portion of the bottom frame section when the bottom frame section is substantially in the open position.
 12. The system of claim 11, wherein the air control device is selected from the group consisting of an air filter, a diffuser, and an insulating block.
 13. The system of claim 10, wherein the wherein the air control device includes a condensation orifice near a center of the device and has a concave surface to enable condensation to be directed into the orifice under a force of gravity and flow through the interchangeable air control device.
 14. The system of claim 10, wherein the at least one air control device is comprised of a first section having a concave surface configured to direct condensation towards a condensation collection orifice located in the first section.
 15. The system of claim 14, wherein the concave surface further comprises a substantially water repellant layer configured to direct the condensation towards the condensation collection orifice to minimize standing water on the concave surface that may cause mold.
 16. The system of claim 14, further comprising a second section comprising a substantially flat panel having a center opening corresponding to the condensation collection orifice located in the first section to enable the center opening to be aligned with the orifice, wherein the second section is located beneath the first section and is supported by the interior stepped portion for the bottom frame.
 17. The system of claim 16, further comprising an attachment device coupled to the second device and located about the center opening, wherein the attachment device is configured to attach a condensation collection unit below the center opening and the condensation collection orifice.
 18. The system of claim 16, wherein the second section is colored and textured to simulate a finish of a ceiling.
 19. The system of claim 17, wherein the attachment device has a finish selected from the group consisting of a gold colored finish, a bronze colored finish, a silver colored finish, and an aluminum colored finish.
 20. The system of claim 17, wherein the condensation collection unit is shaped to resemble a ceiling mounted light fixture cover. 